Background Report Reference...ping), drying, cleaning, headhouse (legs), tunnel belt, gallery belt and belt trippers. Emission factors for these operations at terminal, country and

Background Report Reference

AP-42 Section Number: 9.9.7

Background Chapter: 4

Reference Number: 9

Title: Source Test Evaluation for Feed and Grain Industry

M.P. Schrag et al.

U.S. EPA

December 1976

EPAText BoxNote: This is a reference cited in AP 42, Compilation of Air Pollutant Emission Factors, Volume I Stationary Point and Area Sources. AP42 is located on the EPA web site at www.epa.gov/ttn/chief/ap42/

The file name refers to the reference number, the AP42 chapter and section. The file name "ref02_c01s02.pdf" would mean the reference is from AP42 chapter 1 section 2. The reference may be from a previous version of the section and no longer cited. The primary source should always be checked.

SOURCE TEST EVALUATION

FOR FEED AND GRAIN INDUSTRY

1 I.,

I I I I I I I I I I I 1 I I 1 I I

cma EPA-450/3-76-043

SOURCE TEST EVALUATION FOR FEED AND GRAIN

INDUSTRY

M.P. Schrag, P;G. Gorman. and W.H. Maxwell

Midwest Remarch Institute 425 Volker Boulevard

Kansas City, Miswuri 64110

Contract No. 6842-1403 Tmk Order No. 28

EPA Project Officer: Thomas F. Lahre

Prepared for

ENVIRONMENTAL PROTECTION AGENCY Office of Air and Waste Management

Office of Air Quality Planning and Standards Research Triangle Park. North Carolina 27711

December 1976 .--

I

PREFACE

This r e p o r t was prepared f o r t he Environmental P r o t e c t i o n Agency (EPA) under Contract No. 68-02-1403 (Task 28). The primary purpose of t he work was t o eva lua te emission test da ta f o r country e l e v a t o r s i n order t o r e v i s e and update previous work done by Midwest Research I n s t i t u t e (MRI) f o r EPA t h a t was contained i n t h e EPA Publ ica t ion No. EPA-450/3-75-054 e n t i t l e d "Emission Fac tor Development f o r t he Feed and Grain Industry." The country e l e v a t o r test da ta t h a t were eva lua ted cons is ted of recent tests conducted by MRI f o r EPA a t two e l eva to r s i n Kansas and o t h e r t es t r e p o r t s a t e leva- t o r s i n North Dakota that were suppl ied by M r . Dana Mount of t he North Dakota S t a t e Department of Heal th . M r . Mount's a s s i s t a n c e in t h i s and previous work i s g r a t e f u l l y acknowledged.

T h i s r epor t was w r i t t e n by M r . M. P. Schrag, Head, Environmental Systems Sec t ion , and M r . P. G . Gorman w i t h t h e a s s i s t a n c e of M r . W. H. Maxwell.

Approved fo r : I MIDWEST RESEARCH INSTITUTE

L. J . a n n o n , Di rec tor Environmental and Mater ia l s

Sciences Divis ion I

December 28, 1976

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L i s t o f T a b l e s . . . . . . . . . . . . . . . . . . . . . . . . . . . v i i In t roduc t ion . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Feed and Grain Mills and Elevators . . . . . . . . . . . . . . . . 3

E m i s a i o n F a c t o r s . . . . . . . . . . . . . . . . . . . . . . . . 3 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Emissions and Controls . . . . . . . . . . . . . . . . . . . . 3

Background and Support 1nformatio.n f o r Emission Factors f o r Feed and Grain M i l l s and Elevators . . . . . . . . . . . . . . 11 Genera 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Emissions and Controls . . . . . . . . . . . . . . . . . . . . 11

References . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Appendix A - Emission Fac tors f o r Grain Dryers a t Grain Elevators. 23 Appendix B - Derivat ion of Emission Factors f o r Grain Processing

Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

TABLES

T i t l e

1 P a r t i c u l a t e Emission Factors f o r Grain Eleva tors . . . . 5 - No. -

2 P a r t i c u l a t e Emission Factors f o r Grain Eleva tors Based on Amount of Grain Received o r Shipped . . . . . . . . 6

3 P a r t i c u l a t e Emission Factors f o r Grain Processing Operations . . . . . . . . . . . . . . . . . . . . . . 8

4 P a r t i c u l a t e Emiss ion Factors f o r Grain Eleva tors . . . . 12 5 Best Average Value of Long-Term Composite Emission

Factors f o r a Terminal- Elevator . . . . . . . . . , . . 14 6 Summary of Uncontrolled Emission Fac tor Data From Tests

a t Country Eleva tors . . . . . . . . . . . . . . . . . 14 ? P a r t i c u l a t e Emission Fac tors f o r Grain Eleva tors Based

on Amount of Grain Received o r Shipped . . . . . . . . 15 8 Average Values Used f o r R a t i o of Tons Processed t o

Tons Shipped o r Received . . . . . . . . . . . . . . . 16 9 P a r t i c u l a t e Emission Factors f o r Grain Processing

Operations . . . . . . . . . . . . . . . . . . . . . . 18 A - 1 Summary of Avai lab le Emission Fac tor Data f o r Grain

D r y e r s . . . . . . . . . . . . . . . . . . . . . . . . 24

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.

INTRODUCTION

This t a s k r e p o r t i s a rev ised vers ion of a previous document prepared by MRI f o r EPA e n t i t l e d " h i s s i o n Factor Development f o r t h e Feed and Grain Industry" (EPA-450/3-75-054) da ted October 1974. The sub jec t of this r e p o r t i s emission f a c t o r s f o r g r a i n e l eva to r s and o t h e r feed and g r a i n opera t ions (excluding a l f a l f a dehydration). Consistent with t h e prev ious repor t , t h i s r e p o r t i s arranged a s follows:

m i s s i o n s and Controls

Grain Elevators Grain Processing Operations

Background and Support Information f o r Rnission Fac tors f o r Feed and Grain Mills and Elevators

Grain Eleva tors Grain Processing Operations

Major p o r t i o n s of t h e information and d a t a presented i n t h i s r e p o r t a r e t h e same as t h a t i n t h e prev ious document. The primary d i f f e r e n c e i s t h e r e v i s i o n of some d a t a f o r country e l e v a t o r s based on r ecen t EPA tes ts conducted a t two e l e v a t o r s i n Kansas, and o t h e r r e p o r t s made a v a i l a b l e through t h e North Dakota S t a t e Department of Health. To our knowledge, no o the r new information o r d a t a have become a v a i l a b l e f o r r eeva lua t ion of emission f a c t o r s f o r t h e s u b j e c t sources i n t h e feed and g r a i n indus t ry .

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FEED AND GRAIN MILLS AND ELEVATORS

EMISSION FACTORS

General

Grain e l e v a t o r s a r e t r a n s f e r and s t o r a g e a r e a s f o r g r a i n and a r e usu- a l l y c l a s s i f i e d as e i t h e r country, terminal , o r export e leva tors . Country e l e v a t o r s gene ra l ly r ece ive g r a i n s a s they a r e harvested from f i e l d s within a 10- t o 20-mile r ad ius of t h e e leva tor . The country e l eva to r s unload, weigh and s t o r e g r a i n as i t i s received from t h e farmer. In add i t ion , t h e country e l e v a t o r may dry o r c l ean t h e g r a i n before i t i s shipped t o t h e terminal e l e v a t o r s or processors .

Terminal e l e v a t o r s r ece ive most of t h e i r g r a i n from country e l e v a t o r s and s h i p t o processors , o t h e r terminals , and exporters. The primary func- t i o n of a terminal e l e v a t o r i s t o . s t o r e g r a i n i n quant i ty without de t e r io - r a t i o n and t o br ing i t t o comnercial grade so a s t o conform t o t h e needs of buyers. As with country e l eva to r s , t e rmina ls dry, c lean and s o r t grain. In addi t ion , they can blend g r a i n t o meet buyer spec i f i ca t ions .

Export e l e v a t o r s a r e s imi la r t o te rmina l e l e v a t o r s wi th t h e except ion t h a t they mainly load g r a i n on s h i p s ' f o r export.

The o t h e r types of ope ra t ions involved i n t h e processing of g ra in , i n g r a i n and feed p l a n t s , range from very s imple mixing s t e p s t o complex pro- ces ses which a r e c h a r a c t e r i s t i c of i n d u s t r i a l processing p l an t s . Included a r e such d i v e r s e processes as: ( a ) simple mixing processes i n feed mills, (b ) g r a i n m i l l i n g i n f l o u r mills, ( c ) so lven t e x t r a c t i n g i n soybean process- i n g p l a n t s , and ( d ) a complex s e r i e s of process ing s t e p s i n a corn w e t - m i l l i n g p l an t .

Dnissions and Cont ro ls

Grain handling, m i l l i n g and processing inc lude a v a r i e t y of opera t ions from t h e i n i t i a l r e c e i p t of t h e g r a i n a t e i t h e r a country o r terminal eleva- t o r t o t h e de l ive ry of a f i n i s h e d product. FIour, l i v e s t o c k feed, soybean o i l and corn syrup a r e among t h e products produced from p l a n t s i n t h e g r a i n and feed indus t ry . Bniss ions from t h e feed and g r a i n indus t ry can be sepa- r a t ed i n t o two genera l a r eas , those occurr ing a t g r a i n e l e v a t o r s and those occurr ing a t g r a i n process ing operat ions.

Grain Eleva tors - Grain e l e v a t o r emissions can occur from many d i f f e r e n t ope ra t ions i n t h e e l e v a t o r i nc lud ing unloading ( r ece iv ing ) , loading (shipping) , d ry ing , c leaning, headhouse ( l e g s ) , tunnel b e l t , g a l l e r y b e l t and b e l t t r i ppe r s . Emission f a c t o r s f o r t hese ope ra t ions a t terminal , country and cxport e l e v a t o r s a r e prescnted i n Tablc 1.

Most of t h e emission f a c t o r s shown i n Table 1 f o r te rmina l and export e l e v a t o r s a r e based on r e s u l t s reported i n R e f . 1. Emission f a c t o r s f o r dry ing were based on informat ion i n Refs. 2 and 3. For country e l e v a t o r s , t h e emission f a c t o r s were based on t h e r e s u l t s i n Ref. 1 and s p e c i f i c emis- s ion t e s t s a t country e l e v a t o r s (Refs. 4 t o 9 ) . A l l of t h e s e emission fac- t o r s a r e approximate average va lues intended t o r e f l e c t a v a r i e t y of g r a i n types. Actual emission f a c t o r s f o r a s p e c i f i c source may be considerably d i f f e r e n t , depending on t h e type of g ra in , i.e., corn, soybeans, wheat, and o t h e r f a c t o r s such a s g r a i n qua l i ty .

The emission f a c t o r s shown i n Table 1 rep resen t t h e amount of d u s t generated p e r ton o f ' g r a i n processed through each of t h e des igna ted opera- t i o n s (i .e. , uncont ro l led emission f a c t o r s ) . h o u n t s of g r a i n processed through each of t h e s e ope ra t ions i n a given e l e v a t o r a r e dependent on such f a c t o r s a s t h e amount of g r a i n turned ( i n t e r b i n t r a n s f e r ) , amount dryed, and amount c leaned, etc. Because t h e amount of g r a i n pass ing through each ope ra t ion i s o f t e n d i f f i c u l t t o determine, i t may be more u s e f u l t o express t h e emission f a c t o r s i n terms of t h e amount of g r a i n shipped o r rece ived , assuming these amounts a r e about t h e same over t h e long term. h i s s i o n fac- t o r s from Table 1 have been modified accordingly and a r e shown i n Table 2 a long wi th t h e a p p r o p r i a t e m u l t i p l i e r t h a t w a s used a s r e p r e s e n t a t i v e of t y p i c a l r a t i o s of throughput a t each ope ra t ion t o t h e amount of g r a i n shipped o r received. This r a t i o i s an approximate va lue based on average va lues f o r tu rn ing , c leaning , and drying i n each type of e leva tor . How- ever , ope ra t ing p r a c t i c e s i n ind iv idua l e l e v a t o r s a r e d i f f e r e n t , so these r a t i o s , l i k e t h e b a s i c emission f a c t o r s themselves, would be more v a l i d f o r a group of e l e v a t o r s r a t h e r than ind iv idua l e leva tors .

The f a c t o r s i n Tables 1 o r 2 should no t be added toge the r i n an a t - tempt t o o b t a i n a s i n g l e emission Eactor v a l u e f o r g r a i n e l e v a t o r s because i n most e l e v a t o r s some of t h e ope ra t ions a r e equipped wi th c o n t r o l devices and some a r e not. Therefore, any es t imat ion of emissions must be d i r e c t e d t o each ope ra t ion and i t s as soc ia t ed c o n t r o l device , r a t h e r than t h e ele- v a t o r a s a whole, u n l e s s t h e purpose was t o e s t ima te t o t a l p o t e n t i a l ( i . e . , uncon t ro l l ed ) emissions. An example of t he u s e of emission f a c t o r s i n making an emission inventory i s conta ined i n Ref. 3.

Some of t h e ope ra t ions l i s t e d i n t h e t a b l e s , such as t h e tunnel b e l t and b e l t t r i p p e r , a r e i n t e r n a l o r in-house d u s t sources which, i f uncon- t r o l l e d , might show lower than expected atmospheric emissions because of i n t e r n a l s e t t l i n g of dust . The reduct ion i n emissions v i a i n t e r n a l s e t t l i n g

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Table 1. PARTICUIATE EMISSION FACTORS FOR GRAIN ELEVATOR&?/

Emission f a c t o r (uncontro 1 led):/ Type of source ( l b l t o n ) (kg/MT)

Terminal of e l e v a t o r s

Unloaded ( rece iv ing) Loading (shipping) Removal from b ins ( tunnel b e l t ) Dryin&/ Cleaning- Headhouse ( l egs ) Tripper (ga 1 l e r y b e l t )

c /

Country e l e v a t o r s

Unloading ( rece iv ing) Loading (shipping ) Removal from b ins Dryi&/ Cleanings l Headhouse ( l egs )

Export e l e v a t o r s

Unloading ( rece iv ing) Loading (shipping) Removal from b i n s ( tunnel b e l t ) Drying- b/

Headhouse ( l egs ) R i p p e r ( g a l l e r y b e l t s )

Cleaning- c l

1.00 0.27 1.40 1.05 3.00 1.50 1.00

0.64 0.27 1.00 0.68 3.00 1.50

1.00 1.00 1.40 1.05 3.00 1.50 1.00

- a / Emission f a c t o r s a r e i n terms of poun of g r a i n processed by each source.

o f st e m tel

0.50 0.14 0.70 0.52 1.50 0.75 0.50

0.32 0.13 0.50 0.34 1.50 0.75

0.50 0.50 0.70 0.52 1.50 0.75 0.50

per ton

- b/ Emission f a c t o r s f o r drying a r e based on 1.8 l b / ton f o r rack d rye r s and 0.3 l b / ton f o r column d rye r s prora ted on t h e b a s i s of d i s t r i b u t i o n of t hese two types of d rye r s i n each elevator category, as discussed i n Reference 3.

may range from cO.50 f o r wheat up t o 6.00 f o r corn. - c / Emission f a c t o r of 3.00 f o r c leaning i s an average va lue which

5

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Y

9

Y

Y D

c . "

.... 14 "lOl

6

i s not known and i t is q u i t e poss ib l e t h a t a l l of t h i s d u s t i s eventua l ly emitted t o t h e atmosphere due t o subsequent ex te rna l opera t ions , i n t e r n a l v e n t i l a t i o n o r o the r means.

Many e l e v a t o r s u t i l i z e con t ro l devices on a t l e a s t some sources. In t h e p a s t , cyclones have comonly been appl ied t o such sources as l e g s i n t h e headhouse and tunnel b e l t hooding s y s t e m . More r ecen t ly , f a b r i c f i l - t e r s have been u t i l i z e d a t many e l eva to r s on almost a l l types of sources. However, some sources i n g r a i n e l e v a t o r s do p resen t con t ro l problems. Con- t r o l of loadout opera t ions i s one source t h a t i s d i f f i c u l t t o con t ro l because of t h e problem of containment of t h e emissions. Probably t h e most d i f f i c u l t source t o con t ro l , because of t h e l a r g e flow r a t e and high mois- t u r e content of t h e exhaust gases, i s t h e dryers . Screen-houses 0;' cont inuously vacuumed screen systems a r e a v a i l a b l e f o r reducing d r y e r emissions and have been appl ied a t seve ra l f a c i l i t i e s . Detai led d e s c r i p t i o n s of dus t con t ro l systems f o r g r a i n e l e v a t o r opera t ions and t h e i r estimated c o s t s a r e contained i n Ref. 2.

Grain Processine OD e r a t i o n s - Grain processing ope ra t ions inc lude many of t h e ope ra t ions performed i n a g r a i n e l e v a t o r i n add i t ion t o m i l l i n g and processing of t h e gra in . h i s s i o n f a c t o r s f o r d i f f e r e n t g r a i n m i l l i n g and processing ope ra t ions a r e presented i n Table 3. Brief d i scuss ions of t hese d i f f e r e n t ope ra t ions and t h e methods used f o r a r r i v i n g a t t h e emission fac- t o r va lues shown i n Table 3 a r e presented below.

Bnission f a c t o r d a t a f o r f eed 'mi l l ope ra t ions a r e sparse. This i s p a r t l y due t o t h e f a c t t h a t many ing red ien t s , whole g r a i n and o t h e r dusty m a t e r i a l s (bran, dehydrated a l f a l f a , etc.), a r e received by both t r u c k and r a i l and s e v e r a l unloading methods a r e employed. However, some ope ra t ions (handling, shipping, and rece iv ing) f o r a f eed mill a r e s i m i l a r t o opera- t i o n s i n a g r a i n e l e v a t o r , so an emission f a c t o r f o r each of t h e s e d i f f e r - en t ope ra t ions was est imated on this bas is . The remaining opera t ions were estimated from t h e b e s t information a v a i l a b l e 2 1

Three emission areas f o r wheat m i l l p rocess ing ope ra t ions are g r a i n rece iv ing and handling, c leaning house, and m i l l i n g operat ions. Data from a g r a i n e l e v a t o r s t u d d l were used t o e s t ima te emission f a c t o r s f o r g r a i n rece iv ing and handling. Data f o r t h e c leaning house were i n s u f f i c i e n t t o estimate an emission f a c t o r and information taken from Ref. 2 was used t o estimate t h e emission f a c t o r f o r m i l l i n g opera t ions . The l a r g e emission f a c t o r f o r t h e m i l l i n g ope ra t ion i s somewhat misleading because almost a l l of t h e sources involved a r e equipped with con t ro l devices t o prevent prod- u c t l o s ses and f a b r i c f i l t e r s a r e widely used f o r t h i s purpose.

Operations f o r durum mills and rye m i l l i n g a r e s i m i l a r t o those of wheat mi l l ing . Therefore, most of these emission f a c t o r s a r e equal t o those f o r wheat m i l l operat ions.

Table 3. PARTICULATE EMISSION FACTORS FOR GRAIN PROCESSING OPERATION -1

Emission €acto+ a b l (uncont ro l led except where ind ica t ed )

(kn/biT) Type of source ( l b / t o n )

Feed m i l l s

Receiving Shipping Handling Grinding P e l l e t c o o l e r s

Wheat m i l l s

Receiving Precleaning and handling Cleaning house Millhouse

Durum m i l l s

Receiving Precleaning and handl ing Cleaning house Millhouse

Rye m i l l i n g

Receiving Precleaning and handl ing Cleaning house Millhouse

Dry corn m i l l i n g

Receiving

Precleaning and handl ing Cleaning house Degeming and m i l l i n g

w i n g

1.30 0.65 0.50 0.25 3.00 1.5OcI

0.05- 0.10-/ C l

0.10- 0 . 0 4

1.00 5.00

70.00 -

1.00 5.00

1.00 5.00

70.00 -

1.00 0.50 5.00 6.00 -

0.50 2.50

35.00 -

0.50 2.50 - -

0.50 2.50

35.00 -

0.50 0.25 2.50 3.00

8

Table 3. (Concluded)

Type of source

Oat m i l l i n g

Tota 1

Rice m i l l i n g

Receiving Handling and precleaning Drying Cleaning and millhouse

Soybean m i l l s

Receiving Hand l i n g Cleaning Drying Cracking and dehul l ing Hull g r inding Bean condi t ion ing Flaking Meal d rye r Meal coo le r Bulk loading

Corn wet mi l l i ng

Receiving Hand l i n g Cleaning Dryers Bulk loading

a b / Emission factor- (uncontrol led except where ind ica ted)

( l b l t o n ) (kdMT)

d / 2.50-

0.64 5.00 - -

1.60 5 .OO

7.20 3.30 2 .oo 0.10 0.57 1.50 1.80 0.27

-

1.00 5.00 6.00 - -

d / 1.25-

0.32 2.50 - -

0.80 2.50

3.60 1.65 1.00 0.05 0.29 0.75 0.90 0.14

-

0.50 2.50 3.00 - -

a/ Emission f a c t o r s a r e expressed i n terms of pounds of dus t emit ted per ton of gra in e n t e r i n g the p l an t ( i . e . , r ece ived) , which i s not n e c e s s a r i l y the same a s the amount of m a t e r i a l processed by each operat ion.

- b / Blanks ind ica t e i n s u f f i c i e n t information. - c / Control led emission f a c t o r (cont ro l led with cyc lones) . - d / Control led emission f a c t o r ( I b i s represents s eve ra l sources i n one

p l a n t ; some con t ro l l ed wi th cyclones and others con t ro l l ed with f a b r i c f i l t e r s . )

9

The g r a i n unloading, handling and c leaning ope ra t ions f o r dry corn mi l l i ng a r e s i m i l a r t o those i n o t h e r g r a i n m i l l s bu t t h e subsequent opera- t i o n s a r e somewhat d i f f e r e n t . Also, some drying of corn received a t t h e m i l l may be necessary p r i o r t o s torage. An es t imate of t h e emission f a c t o r f o r drying was obtained from Ref. 2. I n s u f f i c i e n t information was a v a i l a b l e to es t imate emission f a c t o r s f o r degerming and mi l l ing .

Information necessary t o e s t ima te emissions from o a t m i l l i n g was unava i lab le . It was a l s o f e l t t o be unwise t o a t tempt t o u s e emission f a c t o r d a t a f o r o the r g r a i n s because handl ing of o a t s i s report 'ed t o be d u s t i e r than many o the r gra ins . The only emissions f a c t o r d a t a t h a t were a v a i l a b l e were for con t ro l l ed emissions.Z/ An o v e r a l l con t ro l l ed emission f a c t o r of 2 . 5 Ib/ ton w a s ca l cu la t ed from t h i s data.

h i s s i o n f ac to r s , f o r r i c e m i l l i n g were based on those f o r s i m i l a r op- e r a t i o n s i n o t h e r g r a i n handling f a c i l i t i e s . I n s u f f i c i e n t information was a v a i l a b l e t o e s t ima te emission f a c t o r s f o r drying, c l ean ing and mill house operat ions.

Information taken from Ref. 2 w a s used t o e s t ima te emission f a c t o r s f o r soybean mi l l s .

Information on corn wet-mill ing emission f a c t o r s w a s unavai lab le i n most cases due t o t h e wide v a r i e t y of products and t h e d i v e r s i t y of opera- t ions. Receiving, handling and c l ean ing 'operat ions emission f a c t o r s were assumed t o be s i m i l a r t o those for dry corn mi l l i ng .

Many of t h e ope ra t ions performed i n g r a i n m i l l i n g and processing p l a n t s are t h e same a s those i n g r a i n e l eva to r s , so t h e c o n t r o l methods a r e s imi l a r . As i n t h e case of g r a i n e l eva to r s , t h e s e p l a n t s o f t e n use cyclones or f a b r i c f i l t e r s t o con t ro l emissions from t h e g r a i n handling opera t ions (e.g., unloading, legs , c leaners , etc.). These same devices a r e a l s o o f t e n used t o c o n t r o l emissions from o t h e r process ing opera t ions and a good example of t h i s i s t h e ex tens ive u s e of f a b r i c f i l t e r s i n f l o u r mills. However, t h e r e are a l s o c e r t a i n sources wi th in some m i l l i n g ope ra t ions t h a t are not amena- b l e t o use of t hese devices. Therefore, wet scrubbers have found some appl i - ca t ion , p a r t i c u l a r l y where t h e e f f l u e n t gas stream has high moisture content . Cer ta in o t h e r sources have been found t o be e s p e c i a l l y d i f f i c u l t t o con t ro l , and one of t hese i s t h e r o t a r y d rye r s i n wet corn mills. Descr ipt ions of t h e emission con t ro l systems t h a t have been appl ied t o sources wi th in t h e g r a i n m i l l i n g and process ing i n d u s t r i e s are contained i n Ref. 2.

10

BACKGROUND AND SUPPORT INFORMATION FOR EMISSION FACTORS FOR FEED AND GRAIN MILLS AND ELEVATORS

General

Grain e l e v a t o r s a r e t r a n s f e r and s to rage a r e a s f o r g r a i n and a r e usu- a l l y c l a s s i f i e d a s e i t h e r country, terminal , o r export e l eva to r s . Country e l e v a t o r s gene ra l ly r ece ive g r a i n s a s they are harvested from f i e l d s wi th in a 10- t o 20-mile r a d i u s of t h e e leva tor . The country e l e v a t o r s unload, weigh and s t o r e g r a i n as i t i s rece ived from t h e farmer. In add i t ion , t h e country e l e v a t o r may dry o r c lean t h e g r a i n be fo re i t i s shipped t o t h e te rmina l e l e v a t o r s o r processors .

Terminal e l e v a t o r s r e c e i v e most of t h e i r g r a i n from country e l e v a t o r s and s h i p t o processors , o t h e r te rmina ls , and expor te rs . The primary func t ion of a te rmina l e l e v a t o r i s t o s t o r e g r a i n i n quan t i ty without d e t e r i o r a t i o n and t o b r ing i t t o c o m e r c i a l grade so a s t o conform t o t h e needs of buyers. As with country e l e v a t o r s , t e rmina l s dry, c l ean and s o r t grain. I n addi t ion , they can blend g r a i n t o meet buyer s p e c i f i c a t i o n s .

Export e l e v a t o r s a r e similar t o te rmina l e l e v a t o r s wi th t h e except ion t h a t they mainly load g r a i n on s h i p s f o r export .

The o t h e r types of ope ra t ions involved i n t h e process ing of g ra in , i n g r a i n and feed p l a n t s , range from-very simple mixing s t e p s t o complex pro- ces ses which a r e c h a r a c t e r i s t i c of i n d u s t r i a l p rocess ing p lan ts . Included are such d i v e r s e processes as: ( a ) simple mixing processes i n feed m i l l s , (b) g r a i n m i l l i n g i n f l o u r mills, ( c ) so lven t e x t r a c t i n g i n soybean process ing p l a n t s , and (d) a complex series of process ing s t e p s i n a corn wet- m i l l i n g p l an t .

h i s s i o n s and Controls

Grain handling, m i l l i n g and process ing i n c l u d e a v a r i e t y of opera t ions from t h e i n i t i a l r e c e i p t of t h e g r a i n a t e i t h e r a country o r terminal eleva- t o r t o t h e d e l i v e r y of a f i n i s h e d product. Flour, l i v e s t o c k feed , soybean o i l and corn syrup a r e among t h e products produced from p l a n t s i n t h e g r a i n and feed indus t ry . K s s i o n s from t h e feed and grain indus t ry can b e sepa- . r a t e d , i n t o two gene ra l a r eas , those occurr ing a t g r a i n e l e v a t o r s and those occurr ing a t g r a i n process ing operat ions.

Grain Eleva tors - Grain e l e v a t o r emissions can occur from many d i f f e r e n t ope ra t ions i n the e l e v a t o r , inc luding unloading ( rece iv ing) , loading (shipping), d ry ing , c leaning , headhouse ( l egs ) , tunnel b e l t , and b e l t t r i p p e r s (p r imar i ly f o r te rmina l and export e leva tors ) . h i s s i o n s f a c t o r s f o r . sev- e r a l of t h e s e ope ra t ions are presented i n Table 4.

11

Meager s p e c i f i c emission t e s t d a t a a r e a v a i l a b l e from which uncontrol led emission f a c t o r s could be computed. Therefore most of t h e f a c t o r s f o r termi- na l and export e l e v a t o r s a r e based on r e s u l t s repor ted i n Ref. 1, a s summa- r i zed i n Table 5. Recent EPA t e s t r e s u l t s and some emission test r e p o r t s from North Dakota (Table 6 ) were used i n de r iv ing emission f a c t o r s f o r country e leva tors . These t e s t r e p o r t s a r e short-term emission measurements a t a few country e l eva to r s , which were compared with t h e long-term tes t d a t a f o r the terminal e l e v a t o d l i n o rde r t o s e l e c t emission f a c t o r s t h a t may be appro- p r i a t e f o r country e leva tors . The emission f a c t o r f o r drying i s based mainly on d a t a contained i n Refs. 2 and 3, a s discussed i n Appendix A of t h i s re- po r t . A l l o f t hese emission f a c t o r s a r e approximate average va lues intended t o be r e p r e s e n t a t i v e of a v a r i e t y of g r a i n types but , a s noted i n Table 4 and i n t h e re ferences , a c t u a l emission f a c t o r s f o r a s p e c i f i c source could be d i f f e r e n t , depending on t h e type of g r a i n (e.g., c leaning) and many o the r f a c t o r s .

The emission f a c t o r s shown i n Table 4 r ep resen t t h e amount of dus t generated pe r ton of g r a i n processed through each of t h e designated opera- t i o n s (i.e., uncont ro l led emission f ac to r s ) . Amounts of g r a i n processed through each of t hese ope ra t ions i n a given e l e v a t o r a r e dependent on such f a c t o r s as t h e amount of g r a i n turned ( i n t e r b i n t r a n s f e r ) , amount dryed, and amount cleaned. Because t h e amount of g r a i n passing through each opera- t i o n i s o f t e n d i f f i c u l t t o determine, i t may be more use fu l t o express t h e emission f a c t o r s i n terms of t h e amount of g r a i n shipped o r received, assuming these amounts a r e about t h e same over t h e long term. h i s s i o n f a c t o r s from Table 4 have been modified accordingly and a re shown i n Table 7 along with t h e appropr i a t e m u l t i p l i e r t h a t w a s used as r ep resen ta t ive of t yp ica l r a t i o s of throughput a t each opera t ion t o t h e amount of g r a i n shipped o r received. This r a t i o i s an approximate va lue based on average va lues f o r tu rn ing , c leaning , and dry ing i n each type of e l eva to r , as explained i n Table 8. However, opera t ing p r a c t i c e s i n ind iv idua l e l e v a t o r s a r e d i f f e r e n t , so t hese r a t i o s , l i k e t h e b a s i c emission f a c t o r s themselves, would be more v a l i d f o r a group of e l e v a t o r s r a t h e r than i n d i v i d u a l e leva tors .

The f a c t o r s given i n t h e t a b l e s should not be added toge the r i n an a t - tempt t o o b t a i n a s i n g l e emission f a c t o r v a l u e f o r g r a i n e l e v a t o r s because i n most e l e v a t o r s some of t h e opera t ions a r e equipped wi th con t ro l devices and some are not. Therefore, any es t imat ion of emissions must be d i r e c t e d t o each opera t ion and i t s a s soc ia t ed c o n t r o l device, r a t h e r than t o t h e e l - eva tor as a whole, u n l e s s t h e purpose w a s t o e s t ima te t o t a l p o t e n t i a l ( i . e . , uncont ro l led) emissions. An example of t h e use of emission f a c t o r s i n making an emission inventory i s contained i n Ref. 3.

Some of t h e ope ra t ions l i s t e d i n t h e t a b l e s , such a s t h e tunnel b e l t and b e l t t r i p p e r , are i n t e r n a l o r in-house d u s t sources which, i f uncon- t r o l l e d , might show lower than expected atmospheric emissions because of i n t e r n a l s e t t l i n g of dus t . The reduct ion i n emissions via i n t e r n a l s e t t l i n g i s not known and i t i s q u i t e poss ib l e t h a t a l l of t h i s d u s t i s eventua l ly e&ted t o t h e atmosphere due t o subsequent ex te rna l opera t ions , i n t e r n a l v e n t i l a t i o n o r o the r means.

13

Table 5. BEST AVERAGE VALUE OF LONG-TEKM' COMPOSITE EMISSION FACTORS FOR A

TERMINAL ELEVATOR ( L B / T O N ~ /

Rnission f a c t o r Ooeration ( l b / t o n of e r a i n Drocessed)

Truck unloading 0.64 Car unloading 1.30 Car loading 0.27 Corn c l e a n e r 5.18 Gal le ry b e l t 0.11 Tunnel b e l t 1.40 Headhous e 1.49

Table 6 . SUMMARY OF IJNCONTROI ED EMISSION FACTOR FRCM TESTS AT COUNTRY ELEVATORS

TA

Source Emission f a c t o r ( l b / t o n )

and g r a i n type

4 / Unloading ( t r u c k s ) 0.09- (wheat)

Removal from b i n s ( tunne l b e l t 0.68 0.37- 5/ (wheat) hoods and l e g b o o t s , e t c . ) 2.72- 5 / (soybeans)

5 1 0.91- (corn) 5/ - 0.63- (milo)

1.06 avg.

Cleaning

Headhouse ( d i s t r i b u t o r and l e g s , b u t a l s o inc lud ing dump p i t s )

( l e g s only)

14

0.d' (wheat) 0.40- (no t i d e n t i f i e d )

0.34 avg.

0 . 142' (wheat)

0.4$/ (wheat, o a t s , b a r l e y )

1.52- (wheat) 3.47- (milo) - 6.15" (soybeans) 1.98 avg.

7 / 0 .43- . a / (wheat and rye ) -

0.10- 7/ (not i d e n t i f i e d )

4 / 4 /

I 1 I I I 1 I 0 I I 1

O O ~ C I O N ~ ~

A d N 0 0 0 - 4 0 0 0 d N O r - . . . . . . o o w l n o D o 3 O O O N O O

A d N O O O . . . . .

X

O h O r n 0 0 0

d 0 3 d O d d

O N U q q m o . . . . .

a

W 4 h U r( a n

U G J 0 U 15

0 0 N d rn-m o o h o ~ n o . . . . d r ( d 0 0 1 C I d

O o m d m m r - O O N O d N O d r ( r ( 0 0 N d . . . . . . .

o o o m o o o r ( d r ( 3 r n r l d o o * q q ~ o . . .

h U d a n

n U d a n

0 0 0 0 N ( ? r l O O O d N O h

d d N 0 0 0 d . . . . . . .

N N N N N N

0 0 0 . .

+ +

+ +

rl d d h h h . . 0 0 0

+ f +

0 0 0 0 0 0 . . d d rl

+

0 0 0 0 0 0 . . rl rlrl

o o c o l r ) m 0 0 O O O N O O . . . . - ; . ; N o o m

II II 11 II II II

00 00- 0 0 0 0 0 0

+ +

. .

Y I V ) YI N N N

0 0 0 . .

+ +

lr) YI h h

0 0

+ +

0 0 0 0 0 0 4 3 3 . .

+

0 0 0 0 rl 3

z a d P

0

V I W I VI I

fi 3 d d & & p ; - ; . . . :: z VI 3 .A 0 0 0 d r n O h o a l

0 0 N O d N O &

2 22 . . 0 0 0

m a & Y 0 0 u *

a l * - 0 W

& x o c u

g M

2 ; u t 3 o a l

u al * 0

W

m

W Y a a .ri

-5 & 0

x 3 T) a m $ 2: .d 231 p : .

+ + 4 a l a m w * u

d d 4 C * C d C J 0 0 0 0 .A 0

0 0 0 c m V I w m & al M U V I * m m o O S + + n w u u

. .

* i o h h V a l M > 0 0 C W J C

m w 0.4 h 0 . . 0 0 0 d &

c r : + m m m

0 0 0 0 . . dr l

0 0 rl

+ m a l

m u n

M C 0 u 4 o u u o c

u w m 0

* M m V O m > c w * a l m a l a 3 * > a l c a l m

* . u .- VI 0 u > 3 w m 0 0 - c o 3 m

0 8 8 ' d u o z 4 1 u 0 3 3rl i ;: g 2

16

I ’ I I I I I I I

I

I

As mentioned above, many e l eva to r s u t i l i z e c o n t r o l devices on a t l e a s t some sources. I n t h e p a s t , cyclones have c m o n l y been appl ied t o such sources a s l e g s i n t h e headhouse and tunnel b e l t hooding systems. More r e c e n t l y , f a b r i c f i l t e r s have been u t i l i z e d a t many e l e v a t o r s on a l - most a l l sources. However, some sources i n g ra in e l e v a t o r s do p resen t con- t r o l problems. Control of load-out ope ra t ion i s one of t h e more d i f f i c u l t sources t o c o n t r o l because of t h e problem of containment of t h e emissions. Probably t h e most d i f f i c u l t source t o con t ro l , because of t h e l a r g e f low r a t e and high mois ture con ten t of t h e exhaust gases , i s t h e dryers . Screen- houses or cont inuously vacuumed screen s y s t e m s a r e a v a i l a b l e f o r reducing d rye r emissions and have been appl ied a t s e v e r a l f a c i l i t i e s . Detai led de- s c r i p t i o n o f dust c o n t r o l systems f o r g r a i n e l e v a t o r ope ra t ions and their es t imated c o s t s a r e contained i n Ref. 2.

Grain Processine QJ e r a t i o n s - Grain process ing ope ra t ions inc lude many of t h e ope ra t ions performed i n a g r a i n e l e v a t o r i n a d d i t i o n t o m i l l i n g and process ing of t h e grain. Ehiss ion f a c t o r s f o r d i f f e r e n t g r a i n m i l l i n g and processing ope ra t ions a r e presented i n Table 9. Brief d i scuss ions of t h e s e d i f f e r e n t ope ra t ions and t h e methods used f o r a r r i v i n g a t t h e emission fac- t o r va lues shown i n Table 9 a r e presented below. More d e t a i l e d d i scuss ion and d e r i v a t i o n of t h e emission f a c t o r s shown i n Table 9 are presented i n 4 p e n d i x B.

Emission f a c t o r d a t a f o r feed m i l l ope ra t ions a r e sparse . This is p a r t l y due t o t h e f a c t t h a t many ing red ien t s , whole g r a i n and o t h e r dus ty m a t e r i a l s (bran, dehydrated a l f a l f a , e tc . ) , a r e received by both t ruck and r a i l and seve ra l unloading methods a r e employed. However, some ope ra t ions (handling, shipping, and r ece iv ing ) f o r a feed m i l l a r e s i m i l a r t o opera- t i o n s i n a g r a i n e l eva to r , so an emission f a c t o r f o r each of t h e s e d i f f e r - en t ope ra t ions was est imated on t h i s bas i s . The remaining ope ra t ions were est imated from t h e b e s t in format ion avai lable .Z/

Three emission a r e a s f o r wheat mill process ing ope ra t ions a r e g r a i n rece iv ing and handling, c l ean ing house, and m i l l i n g opera t ions . Data from a g r a i n e l e v a t o r stud& were used t o e s t ima te emission f a c t o r s f o r g r a i n rece iv ing and handling. Data f o r t h e c l ean ing house were i n s u f f i c i e n t t o e s t ima te an emission f a c t o r and information raken from Ref. 2 w a s used t o e s t ima te t h e emission f a c t o r f o r m i l l i n g operat ions. The l a rge , emis s ion f a c t o r f o r t h e m i l l i n g ope ra t ion i s somewhat misleading because almost a l l of t h e sources involved a r e equipped wi th c o n t r o l dev ices t o prevent prod- u c t l o s s e s and f a b r i c f i l t e r s a r e widely used f o r this purpose.

Operations f o r durum m i l l s and rye m i l l i n g are s i m i l a r t o those of wheat mi l l i ng . Therefore, most of t h e s e emission f a c t o r s a r e equal t o those f o r wheat m i l l opera t ions .

1 7

-_I

Table 9. PARTICULATE EMISSION FACTORS FOR GRAIN P ROC ES s I NG OPERATION&

me of source

Feed Mi l l s

Receiving Shipping Haniiling Grinding Pe l l e t coo le r s

Wheat Mills


D u m Mills


Rye Mi l l ing


Dry CormMill ing

Receiving Drying Precleaning and handling Cleaning house Degerming and mi l l i ng

m s s i o n factors-/ Luncontrol led except where ind ica t ed )

( l b / t o n ) (kg/MT)

1.30 0.65 0.50 0.25 3.00 1.50

0. l o g 0.05- d/ 0.10- d/ o.os_d/

1.00 0.50 5.00 2.50

70.00 35.00 _ _ --

18

1.00 0.50 5.00 2.50 -- _ _

1.00 0.50 5.00 2.50

70.00 35.00 -_ --

1.00 0.50 0.50 0.25 5.00 2.50 6.00 3.00

Table 9. (Concluded)

i 1 0 I I I I I I I I I I I I I I

Type of source

Emission f a c t o r s A d 1 (uncontrol led except where ind ica ted)

( lb / ton ) (kn/MT)

Oat Mi l l ing

To ta l

Rice Mi l l ing

Receiving Handling and precleaning Drying Cleaning and mil lhouse

Soybean M i l l s

Receiving Handling Cleaning Drying Cracking and dehul l ing H u l l g r ind ing Bean condi t ion ing Flaking Meal dryer Meal coo le r Bulk loading

Corn Wet Mi l l i ng

Receiving Handling Cleaning Dryers Bulk loading

e l 2 . 5 d 1.25-

0.64 0.32 5.00 2.50 -_ -_

1.60 0.80 5.00 2.50

7.20 3.60 3.30 1.65 2.00 1.00 0.10 0.05 0.57 0.29 1.50 0.75 1.80 0.90 0.27 0.14

- - --

1.00 0.50 5.00 2.50 6.00 3.00 -- _ - _ _ --

- a l See Appendix B. - - bl Emission f a c t o r s a r e expressed i n terms of pounds of dus t emit ted pe r ton

of g r a i n en te r ing t h e p l a n t (i.e., rece ived) , which i s n o t necessa r i ly the same a s t h e amount of m a t e r i a l processed by each operat ion.

- c/ - d/ - e/

Blanks i n d i c a t e i n s u f f i c i e n t information. Control led emission f a c t o r ( con t ro l l ed w i t h cyclones). Control led emission f a c t o r (This r ep resen t s several sources i n a n e p l a n t ;

some c o n t r o l l e d with cyclones and o t h e r s c o n t r o l l e d with f a b r i c f i l t e r s . ) 19

-_. The g r a i n unloading, handling and c leaning ope ra t ions f o r dry corn mi l l i ng a r e s i m i l a r t o those i n o t h e r g r a i n m i l l s b u t t h e subsequent opera- t i ons a r e somewhat d i f f e r e n t . Also, some drying of corn received a t t h e m i l l may be necessary p r i o r t o s torage. An e s t ima te of t h e emission f a c t o r f o r drying was obtained from Ref. 2. I n s u f f i c i e n t in format ion w a s a v a i l a b l e t o es t imate emission f a c t o r s f o r degerming and mi l l i ng .

Information necessary t o e s t ima te emissions from o a t m i l l i n g was unavai lab le . It was a l s o f e l t t o be unwise to a t tempt t o u se emission f a c t o r d a t a f o r o t h e r g r a i n s because handling of o a t s i s r epor t ed t o be d u s t i e r than many o t h e r gra ins . The only emissions f a c t o r d a t a t h a t were a v a i l a b l e

2.5 l b / ton was c a l c u l a t e d from t h i s data . were f o r con t ro l l ed e m i s s i o n s 3 f An o v e r a l l con t ro l l ed emission f a c t o r of

h i s s i o n f a c t o r s f o r r ice m i l l i n g were based on those f o r s i m i l a r op- e r a t i o n s , i n o t h e r g r a i n handl ing f a c i l i t i e s . I n s u f f i c i e n t in format ion was a v a i l a b l e t o e s t ima te emission f a c t o r s f o r drying, c l ean ing and m i l l house operat ions.

Information taken from Ref. 2 was used t o e s t ima te emission f a c t o r s f o r soybean m i l l s .

Information on corn wet-mill ing emission f a c t o r s w a s unava i l ab le i n most ca ses due t o the wide v a r i e t y of products and t h e d i v e r s i t y of opera- t ions . Receiving, handl ing and c l ean ing opera t ions emission f a c t o r s were assumed t o be similar t o those f o r dry corn mi l l ing .

20

REFERENCES

1. Gonnan, P. G., "Po ten t i a l Dust h i s s i o n From a Grain Eleva tor In Kansas City, Missouri ," F ina l Report, prepared f o r Environmental P r o t e c t i o n Agency, May 1974.

2. Shannon, L. J., R. W. G e r s t l e , P. G. Gorman, D. M. Epp, T. W. Devitt, and R. h i c k , " h i s s i o n Control i n t h e Grain and Feed I n d u s t r y Volume I - Engineering and Cost Study," F ina l Report by Midwest Research I n s t i t u t e prepared f o r h v i r o n m e n t a l P r o t e c t i o n Agency, Document No. EPA-450/3-73-003aY December 1973.

3. Shannon, L. J., P. G. Gorman, M. P. Schrag, and D. Wallace, "his- s i o n Control i n t h e Gra in and Feed Indus t ry Volume I1 - h r i s s i o n Inventory," F ina l Report by Midwest Research I n s t i t u t e prepared f o r Environmental P r o t e c t i o n Agency, J u l y 1974.

4. Maxwell, W. H., "S ta t ionary Source Tes t ing of a Country Grain Ele- v a t o r a t Overbrook, Kansas," Report prepared by Midwest Research I n s t i t u t e f o r Environmental P r o t e c t i o n Agency, EPA Contract No. 68-02-1403, February 1976.

5. Maxwell, W. H., "S ta t ionary Source Tes t ing of a Country Grain Ele- v a t o r a t Great Bend, Kansas,'' Report prepared by Midwest Research I n s t i t u t e f o r Environmental P r o t e c t i o n Agency, EPA Contract NO. 68-02-1403, Apr i l 1976.

6. Belgea, F. J., "Cyclone h i s s i o n s and Ef f i c i ency Evaluat ion," Report submi t ted t o North Dakota S t a t e Department of Heal th on tests a t an e l e v a t o r i n Fdenburg, North Dakota, by P o l l u t i o n Curbs, Inc., St. Paul , Minnesota, March 10, 1972.

7. Trowbridge, A. L., " P a r t i c u l a t e h i s s i o n Tes t ing - ERC Report No. 4-7683,'' Report submit ted t o North Dakota S t a t e Department of Heal th on Tests a t an e l e v a t o r i n Egeland, North Dakota, by Environmental Research Corporat ion, St. Paul, Minnesota, January 16, 1976.

8. Belgea, F. J., "Grain Handling Dust Co l l ec t ion Systems Evalua t ion f o r Fanners Eleva tor Company, Minot, North Dakota," Report sub- m i t t e d t o North Dakota S t a t e Department of Health, by P o l l u t i o n Curbs, Inc., St. Paul, Minnesota, August 28, 1972.

9. Belgea, F. J. , "Cyclone h i s s i o n and Ef f i c i ency Evaluat ion," Report submit ted t o North Dakota S t a t e Department of Heal th on tests a t an e l e v a t o r i n Thompson, North Dakota, by P o l l u t i o n Curbs, Inc., St. Paul , Minnesota, March 10, 1972.

21

APPENDIX A

EMISSION FACTORS FOR GRAIN DRYERS AT GRAIN ELEVATORS

GRAIN DRYER EMISSION FACTORS

A q u a n t i t a t i v e assessment of emissions from g r a i n d rye r s i s d i f f i c u l t , p r imar i ly because o f lack of a v a i l a b l e da t a . o t h e r informationhave ind ica t ed t h a t the emission r a t e from any given i n s t a l l a t i o n i s dependent upon t h e dryer conf igu ra t ion , i.e., rack o r column; t h e type of g r a i n being processed, i.e., corn , soybeans, wheat; the fo re ign material present i n t he incoming g r a i n , i .e. , d u s t , c h a f f , "beeswing" h u l l s , e t c . ; and t h e amount of m o i s t u r e removed which a f - f e c t s throughput.

The l a r g e volumes of a i r passed through the g r a i n , t h e l a rge c ros s - s e c t i o n a l a r ea through which the a i r i s exhausted and the wide par - t i c l e s i z e d i s t r i b u t i o n of t h e e f f l u e n t c o n t r i b u t e t o sampling d i f - f i c u l t i e s . The absence of an acceptab le test method makes comparisons between repor ted dryer emission t e s t s h igh ly uncer ta in .

A compilat ion of t h e a v a i l a b l e data on emissions test f o r rack and column type d rye r s is presented i n Table A-1 and, based on these d a t a , average values f o r t h e uncont ro l led emission f a c t o r s were s e l e c t e d :

However, these data and

Rack Dryers - 1.8 l b / t o n Column Dryers - 0.3 l b / t o n

Because of t h e small amount of a v a i l a b l e d a t a , spread i n t h e s e d a t a , i n - adequate information regard ing s p e c i f i c t e s t methods, use of d i f f e r e n t sampling t r a i n s , and t h e lack of complete information regarding fo re ign ma te r i a l and moisture d i f f e r e n t i a l , these emission f a c t o r s should only be considered a s i n d i c a t i v e of poss ib l e average emissions and not ab- s o l u t e numbers f o r i nd iv idua l d rye r s .

23

Table A - 1 . SUMMARY OF AVAILABLE EMISSION FACTOR DATA FOR GRAIN DRYERS (UNCONTROLLED)

Rack dryers

(bu/hr) ( lb / ton) Throughput Emission f a c t o r

1,000 3.7- a /

2,000 2.91

500 1.2- b/

b/ 1,500 0.9-

1 .o- b/ 1,800 -

Avg. = 1 .8 l b / t o n

Column dryers Throughput Emission f a c t o r

(bu/hr) ( lb / ton)

400 0.23d

3,000 - O.&/ a / 1,000 0.21-

Avg. = 0 .3 l b l t o n

- a/ Reference 2. h/ Private communication.

24

APPENDIX B

1 . 1 . I I

i I

i

I

I i

DERIVATION OF EMISSION FACTORS FOR GRAIN PROCESSING OPERATIONS (as shown i n Table 9 )

FEED MILLS

Receiving

As s t a t e d i n Reference 2 (p. 159) the ingredien t r ece iv ing a rea repre- s e n t s t he nost s e r i o u s dus t emission problem i n most feed m i l l s . Emia- s i o n f a c t o r da ta f o r t h i s ope ra t ion a r e spa r se , owing p a r t l y t o the f a c t t h a t many i n g r e d i e n t s ; whole g r a i n and o t h e r m r e dusty materials (bran, dehy a l f a l f a , e t c . ) , a r e rece ived , by both t ruck and r a i l and s e v e r a l unloading methods a r e employed. For. t h e s e reasons , an average emission f a c t o r would be d i f f i c u l t to determine, a t l e a s t a s f a r a s whole g r a i n s a r e concerned, so an emission f a c t o r f o r t h e unloading ope ra t ion only has been es t imated a s 1.30 lb / ton . i n t h e Kansas Ci ty e l e v a t o r s t u d y i / fo r c a r unloading and may be re- p r e s e n t a t i v e of feed m i l l s and hopefu l ly r e f l e c t s t h e f a c t t h a t some ing red ien t s tend t o be more dus ty than whole g r a i n s .

Shipping

Most feed m i l l s s h i p the bulk feed by t r u c k , bu t someare a lso shipped i n bags by r a i l and t ruck . major source o f dus t emissions but l i t t l e emission f a c t o r d a t a a r e a v a i l - able. An emission f a c t o r of 0.27 l b / ton was determined f o r c a r loading of g r a i n i n t h e Kansas Ci ty e l e v a t o r study.L/ loading of feed m i l l products would tend t o be mre dus ty than whole g r a i n loading. Therefore , an emission f a c t o r of 0.5 l b / t o n has been est imated for t h i s ope ra t ion .

Handling Operations ( t r a n s f e r p o i n t s , Earner and s c a l e , l e g s 1

No data were a v a i l a b l e f o r t h e i n t e r n a l handl ing ope ra t ions in feed m i l l s . However, i t would be expected t h a t they are somewhat similar t o

This was t h e va lue determined

Reference 2 (p. 166) s ta tes t h a t loadout is a

It i s assumed t h a t bulk

25

those i n g r a i n e l e v a t o r s . the most s i g n i f i c a n t of these ope ra t ions was the legs , having an emis- s i o n f a c t o r of 1.49 lb / ton . The tunnel b e l t f a c t o r of 1.40 lb / ton is s imi l a r but feed m i l l ope ra t ions a r e such t h a t t h i s may not be a com- parable opera t ion . However, a l l ma te r i a l i n a feed m i l l would be expected t o pass through a leg a t l e a s t twice from unloading t o shipping. Therefore , an o v e r a l l average emission f a c t o r f o r feed m i l l handling ope ra t ions has been es t imated a s 3.0 lb / ton .

Grinding

Whole g r a i n s rece ived a t feed m i l l s must be ground and t h e a s soc ia t ed product recovery cyclone is t h e major dust source i n t h i s g r a i n prep- a r a t i o n opera t ion . Because of t h e wide v a r i a t i o n i n g r a i n s and g r i n d e r s used, an average emission f a c t o r would be d i f f i c u l t t o d e t e r - mine. A small amount of da ta presented i n Reference 2 (p. 163) i n - d i ca t ed t h a t c o n t r o l l e d emissions may range from 0 . 0 2 t o 0.2 lb / ton . Considering these f a c t s , and lack o f o the r da t a , an average c o n t r o l l e d emission f a c t o r of 0.1 l b / t o n has been es t imated , assuming it is t o be r e p r e s e n t a t i v e of t h e indus t ry a s a whole.

The Kansas City e l e v a t o r study- 1/ showed t h a t

P e l l e t Coolers

The only a v a i l a b l e emission f a c t o r da ta for t h i s opera t ion was contained i n Reference 2 (pp. 164-167) and ind ica t ed t h a t t h e uncontrol led emission f a c t o r was q u i t e high (5 t o 50 l b / t o n ) but t h a t t he cyclones were very e f f i c i e n t (92 to 99.9%). The da ta on p. 164 show cons iderable d i f - ference i n c o n t r o l l e d emission f a c t o r s fo r h o r i z o n t a l coo le r s and column coolers . D i s t r i b u t i o n o f t hese two types of coo le r s wi th in the indus t ry is not known b u t our observa t ions i n d i c a t e t h a t column coo le r s a r e q u i t e common. For t h i s reason, a c o n t r o l l e d emission f a c t o r of 0 .1 l b / t o n has been est imated.

WHEAT MILIS

Processing ope ra t ions were d iscussed i n Reference 2 (p. 207) and i d e n t i - f i e d t h r e e emission a reas : house, and m i l l i n g opera t ions . Emission f a c t o r s and c a l c u l a t i o n o f emissions f o r sources wi th in each of these ope ra t ions is discussed below.

g r a i n rece iv ing and handl ing, c leaning

Receiving

It would be expected t h a t r ece iv ing of wheat would be s i m i l a r in emissions t o thar f o r terminal g r a i n e l e v a t o r s (0.64 and 1.30 lb/ ton) .1/ Data on

26

I I I

I I

p. 122 of Reference 2 p re sen t s con t ro l l ed emission f a c t o r s f o r f a b r i c f i l - t e r s but it i s d i f f i c u l t t o u s e these d a t a i n es t imat ing an uncontrol led f ac to r . Therefore, t h e d a t a from Reference 1 had t o be used, and an average f a c t o r of 1.0 l b / t o n was s e l e c t e d f o r r ece iv ing by t rucks , cars, and barges.

Precleaning and Handling

Very l i t t l e da ta on uncontrol led emissions from prec leaning were a v a i l - a b l e , bu t i t is assumed t o c o n s i s t p r imar i ly o f s ca lp ing type opera t ions , which should be a minor source i n comparison wi th handl ing opera t ions . Handling c o n s i s t s of l egs , t r a n s f e r p o i n t r , garner and scale and t r i p p e r , ' e t c . Usable da t a on uncontrol led emission f a c t o r s f o r t hese sources i n f l o u r millswere lacking , so t h e da t a from Reference 1 had t o be used, even though i t w a s f o r a g r a i n e l eva to r and d i d n o t include a t r i p p e r . However, i t d id include a tunnel b e l t and i t is a l s o known t h a t i n a f l o u r m i l l the g r a i n would pass through t h e leg twice (once when received and once when t r a n s f e r r e d t o c leaning house). Therefore , a cumulative emission f a c t o r of 5.0 l b / ton was es t imated f o r a l l pre- c leaning and handl ing opera t ions .

Cleaning House

Cleaning is accomplished by a v a r i e t y of means bu t o f t e n inc ludes a i r a s p i r a t i o n t o r e m v e l i g h t e r impur i t i e s (dust) as w e l l a s d i s c sepa ra to r s and scourers . Each of these can be a source o f dus t emissions but on ly a small a m u n t of emission d a t a on cyclone c o n t r o l l e d sources were a v a i l - a b l e i n Reference 2 (p. 210). Therefore, i t w a s n o t f e a s i b l e t o c a l - c u l a t e an emission f a c t o r f o r t h e c leaning house.

M i l l House

Operations i n t h e m i l l house are complex, and aga in , very l i t t l e emission da ta a r e ava i l ab le . Reference 2 (p. 209) c i t e s one r e p o r t which ind ica t ed t h a t d u s t generated i n r o l l e r m i l l s may average 2.1 lb/bu (70 lb / ton) . This source and t h e p u r i f i e r s might t he re fo re account f o r mre than 70 lb / ton . This emission f a c t o r is l a r g e r than t h e one f o r precleaning and handling and may be erroneously high but i t was t h e only d a t a ava i l ab le . It should be noted t h a t because of the product value these emissions a r e con t ro l l ed , p r imar i ly wi th f a b r i c f i l t e r s .

21

DURUM MILLS

The sources of a i r p o l l u t i o n i n a durum m i l l p a r a l l e l those of a f l o u r m i l l and f a l l i n t o the t h r e e main ca t egor i e s of r ece iv ing and handling opera t ions , cleaning-house, and m i l l i n g opera t ions . Rate of emission fo r durum m i l l ope ra t ions a re l imi t ed but s i n c e t h e processing opera t ions a r e s i m i l a r t o those of a f l o u r m i l l , t he r a t e s a r e expected t o be s i m i l a r (Reference 2 , p . , 215) . However, i n t h e m i l l s e c t i o n one of the primary purposes i s t o produce middlings r a t h e r than f l o u r so the break r o l l s a r e d i f f e r e n t . Because o f t h i s , i t is assumed t h a t the emission f a c t o r of 70 lb / ton used f o r t h e m i l l house i n f l o u r m i l l s may not be app l i cab le t o durum m i l l s . Therefore, t h e same emissfon f a c t o r s f o r f l o u r m i l l s were assumed t o apply, bu t t h e emission f a c t o r f o r mi l l i ng ope ra t ions was not es t imated.

RYE MILLING

The m i l l i n g procedure f o r r y e c o n s i s t s of t h e same process ing s t e p s a s wheat mi l l i ng (Reference 2 , p. 221) and a i r p o l l u t i o n sources p a r a l l e i those i n a wheat m i l l . Very l i t t l e emission f a c t o r da t awere a v a i l a b l e f o r rye mi l l i ng . Some d a t a on c e r t a i n mi l l i ng ope ra t ions (Reference 2 , p. 226) i n d i c a t e a c o n t r o l l e d emission f a c t o r of about 1 lb/ ton. This i s equiva len t t o an uncontrol. led emission f a c t o r of 10 l b / t o n , assuming cyclone e f f i c i enc ie so f909 . . However, these da ta do not include break r o l l s and o t h e r opera t ions so t h e f a c t o r of 70 lb / ton used f o r wheat mi l l i ng was assumed to be app l i cab le t o rye. This f a c t o r , and t h e o t h e r s f o r wheat mi l l i ng were assumed t o be t h e same f o r rye mi l l ing .

DRY CORN MILLING

The g r a i n unloading, handling, and c leaning ope ra t ions are similar t o those i n o t h e r g r a i n m i l l s b u t t h e subsequent ope ra t ions a r e somewhat d i f f e r e n t (Reference 2, p. 216) . Very l i t t l e emission f a c t o r da ta were a v a i l a b l e f o r d r y corn mi l l i ng , except f o r some c o n t r o l l e d emission f a c t o r s t abu la t ed i n Rtference 2 (pp. 222, 223) .

Receiving

As i n the case of f l o u r m i l l s , an average emission f a c t o r o f 1.00 lb / ton has been used f o r t h e r ece iv ing opera t ion .

Drying

Some drying of corn rece ived a t the m i l l may b e necessary p r i o r t o s torage . Types of d rye r s used (rack o r column) is not known, but about 509. use t h e

28

I ! I ; I I I I I 1 I I I

, I

Day-Vac system. For t h i s reason, an emission f a c t o r of 0 . 5 l b / t o n was used based on dryer emission f a c t o r s discussed i n Appendix A.

Precleaning and Handling

As explained i n t h e s e c t i o n on f lour m i l l s , an average emission f a c t o r of 5 . 0 l b / ton was used f o r t h e precleaning and handling opera t ions .

Cleaning House

An emission f a c t o r of 5.78 l b / t o n was determined f o r a g r a i n e l e v a t o r corn c leaning opera t ion . i / Also, Reference 2 (p. 222) shows an emis- s ion f a c t o r of 0.0015 lb/bu (0.06 lb / ton) f o r a c leaning house con t ro l - l ed by a f a b r i c f i l t e r . If the FF were 997. e f f i c i e n t , t h e equiva len t uncontrol led f a c t o r would b e 6.0 lb / ton , which agrees c l o s e l y wi th t h e previous f a c t o r of 5.78 lb / ton .

Degerming and .Mi l l ing

Emission f a c t o r d a t a w e r e n o t ava i l ab le .

OAT MILLING

Most of t h e information necessary f o r es t imat ing emission f a c t o r s was n o t ava i l ab le . It was f e l t t o be unwise t o a t tempt t o use emission f a c t o r da t a f o r o t h e r g r a i n s because handl ing of o a t s i s repor ted t o be d u s t i e r than many o t h e r g ra ins . The only emission f a c t o r da t a t h a t were a v a i l a b l e con'tained c o n t r o l l e d emission f a c t o r s only (Reference 2, p. 236) which can be used t o c a l c u l a t e an o v e r a l l f a c t o r of 0.04 lb/bu o r 2.5 l b / ton . It is not known i f t h e s e d a t a , f o r one m i l l , included most major d u s t sources nor i s i t known i f this p l a n t , and t h e c o n t r o l devices used (cyclones and f a b r i c f i l t e rs ) , are r e p r e s e n t a t i v e of t h e industry. However, both of t h e above were assumed t o be t rue , and t h e t o t a l con t ro l l ed emission f a c t o r of 2.5 lb / ton was used.

RICE MILLING

Emission f a c t o r da t a f o r r i c e mi l l i ng opera t ions aremeager. Emission sources a s soc ia t ed with r ece iv ing , c leaning and s to rage are s i m i l a r t o those involved wi th a l l g r a i n !processing but i t is not known i f r i c e emits more o r l e s s ' d u s t than o the r g r a i n s i n these opera t ions . However, emission f a c t o r s f o r o t h e r g ra ins were used.

,

Receiving

Data i n Reference 2 (p. 471) t ruck. An emission f a c t o r f o r t r u c k unloading of 0.64 l b / ton was assumed based on data f o r a terminal g r a i n e l e v a t o r . l /

Handling and Precleaning

As was explained i n the s e c t i o n on wheat m i l l s , a cumulative emission f a c t o r of 5.0 l b / t o n has been assumed f o r t he similar opera t ions i n a r ice m i l l .

i n d i c a t e t h a t most r ice i s received by

Drying

Observation of r i c e dryers i n d i c a t e s t h a t the emission f a c t o r may be considerably h igher than f o r drying of o t h e r g r a i n s but support ing data were not ava i l ab le .

Cleaning and M i l l House

Because of t he lack of da t a , no estimate of t h e emission f a c t o r could be made.

SOYBEAN MILLS

Receiving

Data i n Reference 2 (p. 251) i n d i c a t e an average con t ro l l ed emission f a c t o r f o r a t ruck dump p i t of 0.017 lb / ton , o r an uncontrol led f a c t o r of 1.5 l b / t o n assuming 99% e f f i c i e n c y f o r t h e f a b r i c f i l t e r con t ro l device. This i s i n good agreement w i t h da ta i n Reference 1 f o r soybeans which showed 1.63 l b / t o n f o r t ruck unloading and .1.51 l b / t o n f o r c a r unloading. Therefore , an emission f a c t o r of 1.6 l b / ton was used f o r soybean receiving.

Handling

No s p e c i f i c information was a v a i l a b l e on emission f a c t o r s f o r soybean handl ing opera t ions . Even though the emissions from soybeans may be higher than o t h e r g r a i n s t h e cumulative f a c t o r of 5.00 lb / ton , as d i s - cussed i n t h e wheat m i l l i n g s e c t i o n , was used.

30 -

i

Cleaninq

No information was ava i l ab le on the cleaning of soybeans although it i s suggested t h a t it would be a t least as much as the 6 .00 l b / t o n discussed i n the s e c t i o n on dry corn mi l l ing .

DrVing

Soybean p l a n t s do dry t h e feed to t h e f l a k i n g m i l l and observat ions have ind ica ted t h a t the emission f a c t o r f o r drying of soybeans a t soybean m i l l s may be higher than the average f a c t o r s discussed i n Appendix A. The only da ta a v a i l a b l e on soybean dryers a re contained i n Reference 2 (p. 255) and havebeen used to c a l c u l a t e uncontrol led emission f a c t o r s ranging from 4 .2 t o 80 lb / ton . The value of 80 l b / t o n i s very high but even d is regard ing t h i s va lue , t h e average f a c t o r is 7 . 2 Ib/ ton.

Cracking (and dehullinR)

Data presented i n Reference 2 (p. 2 5 6 ) show t h a t t h e con t ro l l ed emission f a c t o r f o r cracking and dehul l ing opera t ions is on t h e order of 0.01 lb/bu, o r 0.33 lb / ton . con t ro l devices , t h e uncontrol led emission f a c t o r would be 3.3 Ib/ton.

I f one assumes 90% e f f i c i e n c y f o r t he cyclone

H u l l Grinding

Control led emission f a c t o r s for h u l l g r ind ing i n Reference 2 (p. 256) show an average, f o r t h ree r epor t ed values , of 0.0055 lb/bu o r 0.18 l b / ton Again assuming 90% e f f i c i e n c y f o r t h e cyclone c o n t r o l devices , the uncon t ro l l ed . emis s ion factor would be approximetely 2 .0 lb/ ton.

Behn Conditioning

Reference 2 (p. 256) shows a cyclone con t ro l l ed emission f a c t o r of 0.0003 lb/bu o r 0.01 l b / ton . Assuming 90% cyclone e f f i c i e n c y , t h e uncontrol led emission f a c t o r i s 0.1 lb / ton .

F lak ing

A t o t a l of four con t ro l l ed emission f a c t o r s f o r f l a k i n g a r e presented i n Reference 2 (pp. 2 5 2 , 256 ) and show an average of 0.0017 lb/bu o r 0.057 lb / ton . These were each cyclone con t ro l l ed , so assuming 90% e f f i c i e n c y , t he uncontrol led emission f a c t o r would be 0.57 lb / ton .

31

Meal Drver

Cyclone con t ro l l ed emission f a c t o r f o r meal d rye r s was presented i n Reference 2 (pp. 252, 256) and showed a range of 0.003 t o 0.0128 lb/bu with an average of 0.0045 lb/bu o r 0.15 lb / ton . e f f i c i e n c y f o r t h e cyclones, t h e uncontrol led f a c t o r would be 1.5 lb/ ton.

Again assuming 90%

M A Cooler

Only one cyclone c o n t r o l l e d emission f a c t o r was a v a i l a b l e (Reference 2 , p. 252); 0.0056 lb/bu o r 0.18 lb / ton . cyclone, t h e uncont ro l led f a c t o r would be 1.8 lb / ton .

Assuming 90% e f f i c i e n c y f o r the

Bulk Loading

No emission f a c t o r d a t a w e r e a v a i l a b l e fo r meal loading. However, observat ion of these ope ra t ions ind ica t e s t h a t it may be about ?he same a s loading g r a i n a t e l e v a t o r s o r about 0.27 lb/ ton. l /

CORN WET MILLING

Receiving

Corn i s received by c a r s and t rucks and, a s was done fo r dry corn m i l l s , a n average emission f a c t o r of 1.0 l b / t o n was used.

Handling

Emission f a c t o r s s p e c i f i c a l l y app l i cab le t o handl ing of corn a t w e t corn m i l l s a r e not a v a i l a b l e . average cumulative emission f a c t o r o f 5.0 l b / ton was used.

However, a s was done on d ry corn m i l l s , an

Cleaning

An emission f a c t o r of 6.0 l b / ton f o r corn cleaning, a s developed i n the s e c t i o n on dry corn m i l l s , was used.

Dryers

Feed, g l u t e n and germ d rye r s a r e a major source of emissions from w e t corn m i l l s bu t emission factor da ta a re l ack ing .

Bulk Loading

Bulk loading of products i s another p o t e n t i a l source of emissions but no emission f a c t o r da ta a r e ava i l ab le .

32

I . REPORT NO.

I I I. TITLE A N 0 SU0TlTLE 15. REPORT DATE

2. 3. RECIPIENT'S ACCESSIOWNO.

December 1976 6. PERFORMING ORGANIZATION CODE Source Test Eva lua t i on For Feed And Gra in I n d u s t r y

'. 4UTHORISl

M.P. Schrag, P.G. Gorman and W.H. Maxwell

Midwest Research I n s t i t u t e

Kansas City, M issour i 64110

PERFORMING ORGANIZATION NAME A N D ADDRESS

425 Vol k e r Boulevard,

2 . SPONSORING AGENCY N 4 M E A N D ADDRESS

8. PERFORMING ORGANIZATIDN REPORT N(

10. PROGRAM ELEMENT NO,

11. CONTRACTIGRANT NO.

68-02-1403 13. TYPE OF REPORT A N D PERIOD COVEREC

O f f i c e o f A i r Q u a l i t y P lanning and Standards Mon i to r i ng and Data Ana lys is D i v i s i o n Research T r i a n q l e Park, Nor th Caro l i na 27711

5. ABSTRACT

This r e p o r t i s a r e v i s e d v e r s i o n o f a p rev ious document prepared by M R I f o r EPA e n t i t l e d "Emission Fac tor Development f o r t h e Feed and Gra in 1ndustr.y" (EPA-450/3-75-054) dated October 1974. f a c t o r s f o r g r a i n e l e v a t o r s and o t h e r feed and g r a i n ope ra t i ons (exc lud ing a l f a l f a dehydra t ion) .

same as t h a t i n t h e prev ious document. some data f o r coun t ry e l e v a t o r s based on recen t EPA tes ts conducted a t two e l e v a t o r s i n Kansas, and o t h e r r e p o r t s made a v a i l a b l e through t h e Nor th Dakota S t a t e Departmen of Hea l th . To ou r knowledge, no o t h e r new i n f o r m a t i o n o r data have become a v a i l a b l e f o r r e e v a l u a t i o n o f emission f a c t o r s . f o r t h e s u b j e c t sources i n the feed and g r a i n i ndus t r y .

The s u b j e c t o f t h i s r e p o r t i s emission

Major p o r t i o n s o f t h e i n f o r m a t i o n and.data presented i n t h i s r e p o r t a re t h e The pr imary d i f f e r e n c e i s t h e r e v i s i o n o f

'L

14. SPONSORING AGENCY CODE

K E Y WORDS A N D DOCUMENT ANALYSIS

l lnr l a c z i fi tad . . 20. SECURITY CLASS (The pallel

U n c l a s s i f i e d Release U n l i m i t e d

~ ~~

DESCRIPTORS Ib.lDENTIFIERS/OPEN ENDED TERMS IC. COSATI FieldICroup I I

17 22. PRICE

Emission Factors Gra in E leva tors Gra in Processing P a r t i c u l a t e Emission Fac tors

.OISTRIBUTION STATEMENT I l9 .SECURITY CLASS l77titRepon) 121. NO, OF PAGES

l lnr l a c z i fi tad . . 20. SECURITY CLASS (Thepal le l

U n c l a s s i f i e d Release U n l i m i t e d 17

22. PRICE

A Form 2220-1 19.73)

Documents

Background Report Reference...ping), drying, cleaning, headhouse (legs), tunnel belt, gallery belt and belt trippers. Emission factors for these operations at terminal, country and